My 86 Re-build

hllon4whls

I am just getting started. My hesitation is waning, so I am getting into things.

These are the pictures of it partially stripped down. I have all of the body pieces in more or less good shape. The lower portion of the panels are rusted, so the plan is to replace that with some diamond plate. Not sure if I will go shiny or satin black.

Certain plans for the cart are 100% moving parts and electrical will function as close to new as possible. Other plans are flat black panels and led front and rear lights.

As you can see from the pictures, the rockers are toast. I am replacing that with some angle steel. Its mild steel from bed frame and its about 1 1/4 by 1/8 thick. I will weld it to the main frame with 4 or more pieces. The stock supports are gone.

Looks like I have the two outboard battery boxes to fix. The other boxes were fixed in an ok manner and are still very solid.

Things that need to be fixed: resistor pack, throttle contacts, lead for throttle contacts, brakes, all wiring, key switch.

Battery Compartment

Front

Rear

Rusted

Rocker

Rocker Removed

Rocker Mocked Up - Will weld in section to fill the bend gap


Let me know any suggestions. Thanks!

BGW

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groundpounder

great project..

gatormeup

just got through doing something like this on my 91, mine didnt look to be quite as bad, good luck with it, my sons helped me and really enjoyed it!! good learning experience for them!!(Save their money and buy good shat) jk...... hope i taught them a little about mechanicing<<sp?????? well anyway good luck to you!! have fun with it... i have some pics of my rebuild and lift on my other post about offset wheels!!

hllon4whls

I finally had a day to make some progress on the build. It took all day to strip off the floor boards and the front of the battery compartment.

I think the new rockers came out good. They go farther back that the stockers I believe, but they intersect the fender and tuck nicely under. They are only visible through the front of the rear tire opening.

I added the gusset to the frame because once I welded the supports, it still moved easily. That fixed it, it doesn't move at all now. I jumped on it and its solid.

I haven't looked for it yet, but I need a new boot for the rack on the steering. Can I get that piece?


High Shot

Low Shot

hllon4whls

I've got my parts on order. I suspected that some of it would have been here by friday, but I didnt get one piece. I may try to spray some of the body this weekend after I BBQ some steaks.

Anyway, last week I brush painted the frame with POR15. I like this stuff, but its pricey. $35 per quart. It really likes to go on over rust. Coats better over rust than it does over plain metal. I just slopped it on to get coverage. I have a few spots to touch up. This stuff is the ultimate threadlocker. If you want to unbolt a bolt, dont get it on the threads.

Here is the battery area of the frame. ITs looking pretty good, I think.



Here are the two outboard battery boxes that I built yesterday.



And here is my front end. Why is my frontend different than all others I have seen. All other pictures and lift kits show a C around the spindles. Mine sit on top of the axle. Can the newer style front end take my spindles if I wanted to change it out? Got a little carried away with the POR15.

scottyb

NIce job on the battery boxes and all the frame repair Did your cart have a ID tag can you give the manufacture code from the serial # tag?
Maybe a real old front end? It does look upside down except the shock mounts are up? Wonder if you couldn't turn it over and relocate the shock mounts? Jus thinking out loud....flip it end for end and rol it over in a cartwheel motion? Might give about a 4" lift?

hllon4whls

Thanks.
The ID tag seemed to indicate 86 from what the board has explained to me.

I was thinking somewhat of the same thing. If I grafted on some C holders for the spindles/kingpins that might give it a 2.5 inch higher stance. The back would be easy to add some height to.

iaefebs

I think your front end is standard. I looks just like mine. I have a 88 marathon. Just to let you know the rear of your cart is from a 1986 1/2-1987. Motor upgrades are not readily available. The rear axle is uncommon since the input gear and motor shaft are keyed and not 19 splines. If you end up ordering a manual or look for info on the rear you need to be aware of this. I have the same rear in my 88 (a previous owner swap). I plan on using the cart for golf so I will not be doing an upgrade on the motor.

hllon4whls

Good to know, but motor swap is not on the agenda. I'll probably do nothing to the performance, but 48v at a max and 48v and/or a controller at absolute max. I have no real need for the cart. I'll make it work 100% then possibly sell it. First things first, I have to get it drivable.

hllon4whls

OK. Its Sunday evening, time for an update post.

I got some stuff done this weekend. Not what I wanted to complete, but a solidly productive day in my opinion. BTW its HOT out.

The rear battery box supports were original and they were perforated, so I cut them out and replaced with some similar strapping. Here they are from the rear.



I also mounted the outboard battery boxes that I made last weekend. That came out well. I came dangerously close to the rear spring mount but it didnt interfere. I had that sinking feeling when I noticed it. Of course that was after I had fully welded in each box.



Lastly I found a place for the resistor coils and got that all mounted up. The original box that it came in is just trashed. I don't know where the resistor pack was originally because when I got the cart, it was just flopping around inside. I may try to fab up a sheet metal cover, but I doubt it. I don't plan to be in that compartment very often. I took the longer route in mounting it because I wanted it as far away from the batteries as I could. I kept it close to the wiper so that I could keep the cables short.





I also took the brakes apart today. The passenger side was really toast. The hub was seized onto the shaft. I had to unbolt the backing plate and whack the crap out of it with a 5lb hammer to get the thing apart. In the process of getting it apart, I knocked both the shoes off the shoe plate. I'll have to get some new brake shoes.

I want to try to paint the whole rear end housing and get it back together next weekend. I would also like to wire the whole thing up and at least go through a test ride sitting on just the skeleton. I figured that was not a good idea without brakes. Body panels will be painted in a couple of weekends, hopefully. The humidity is so high, it may be a challenge.

BTW, simply because I have it, I am going with all 2awg wire. The wiper wire will be the only wire under 2awg. I work in telecom and pick up scraps. This all of the 2awg that I have which I think is just enough to do the cart.

Thanks for the sticky on the brakes!